Numerical simulation of 3D unsteady aluminium extrusion process using finite volume method based on non-orthogonal block structured grids

The mathematic model of three-dimensional aluminium profile extrusion processes using the finite volume method was established in the present paper. Basic theories and key technologies of the Simple method using the collocated arrangement strategy based on boundary fitted non-orthogonal block structured grids were studied. The governing equations were directly discretised on boundary fitted non-orthogonal grids. The coordinate transformation between the Cartesian rectangular coordinateand the curvilinear coordinate was avoided. The negative effects of grids' non-orthogonality, such as the dislocation between the lines connecting the centre points of adjacent elements and the centre of their interface, were compensated. The volume of fluid (VOF) scheme was used to capture the free surface of the deforming material. A program was written according to the above theories and equations. A typical three-dimensional aluminium profile extrusion process was simulated by use of the program developed in the present paper. The simulation results were also compared with that simulated by Deform-3D in the same process, material and die conditions. The feasibility of the mathematic model built in the present paper was demonstrated by the simulation results and the comparison.